Direct drive windshield wiper assembly

ABSTRACT

A windshield wiper assembly including at least one motor having an output shaft and a windshield wiper operatively connected to the output shaft. The motor includes a stator adapted to provide an electromagnetic flux and a rotor assembly supported for rotation about the stator. The rotor assembly includes a back iron that defines an inner circumference and a plurality of magnets disposed in spaced parallel relationship relative to one another about the inner circumference of the back iron and in radially spaced relationship about the stator. The rotor assembly is operatively connected to the output shaft and responsive to electromagnetic flux generated by the stator so as to provide a rotational force to the output shaft to drive the windshield wiper in repeated wiping motion across the windshield.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application is a continuation-in-part of U.S. Ser. No.10/146,190, filed May 15, 2002, entitled “Direct Drive Windshield WiperAssembly,” issued on Sep. 20, 2005 having U.S. Pat. No. 6,944,906.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to windshield wiper systems and,more particularly, to a windshield wiper system that utilizes individualdirect drive motors for coordinated, but mechanically independent,control of the windshield wipers.

2. Description of the Related Art

Windshield wiper systems commonly employed in the related art includepivotally mounted wiper blades that are oscillated across a windshieldbetween an in-wipe position, typically located near the cowl of anautomotive vehicle, and an out-wipe position, usually associated with anA-pillar on the vehicle, in the case of the driver side wiper blade inthis representative example. It is typically desirable to maximize theangular velocity of the blade assemblies between the in-wipe andout-wipe positions where the blade assembly is moving across thewindshield in front of the driver to reduce the duration of each wipecycle. On the other hand, it is also desirable to limit noise andinertia loading by reducing the velocity of the blade assemblies as theyapproach the wipe limits. These are two competing objectives that mustbe balanced in order to be successfully and economically obtained.

One long-standing design approach that has been employed in the relatedart includes the use of a single motor assembly, driven in onerotational direction, driving two separate wiper arms across thewindshield of a vehicle. This approach requires a fairly complex linkagesystem to convert the singular angular motion of the wiper motor intothe two-way linear reciprocal motion to drive both wiper arms. In thedashboard-firewall area, where these systems are typically installed,this mechanical linkage requires a large amount of underhood space.Moreover, the area near this moving linkage must be kept clear of wiresand other vehicle components. Additionally, the moving linkage, with itsseveral pivot and rotational points is subject to mechanicalinaccuracies and wear, readily introducing excessive wiper movement.

Nevertheless, for many years, designers and manufacturers were reluctantto depart from this established approach. However, improved vehicleaerodynamics that have fostered vehicle designs having longer slopedfront surfaces are leading to windshield designs with more pronouncedrake angles that result in larger window surfaces. A wiper system forsuch windshields must therefore include longer, more massive wiper armsand blades to wipe the required percentage of the larger surface. Thishas created a number of problems. Most notably, the larger arms andswept surface area increases the size of conventional wiper systems tosuch an extent that it becomes difficult to fit a single motor systemwithin the typically allotted underhood space. This problem is furtheraggravated by the same aerodynamic sloped front surfaces of the newervehicle designs, which reduce the available underhood space.Additionally, the larger area to be swept by the wiper system requiresmore power and control over the wiper arm that can be provided by alinkage type system.

In response to the changes in vehicle front face design and the loss ofavailable underhood space, the dual motor wiper system has evolved.Representative examples of such systems can be found in U.S. Pat. No.4,585,980 to Gille et al.; U.S. Pat. No. 4,665,488 to Graham et al.;U.S. Pat. No. 4,900,995 to Wainwright; and U.S. Pat. No. 5,252,897 toPorter et al. These wiper systems are generally directly driven.Additionally, U.S. Pat. No. 5,355,061 to Forham employs a brushless dcmotor to operate a direct drive windshield wiper system, as do othersthat follow. The more recent direct drive wiper blade systems employingdual motors have utilized some hardware and/or software controlledswitching scheme to control each individual motor, in reference to theother, to provide blade control across the windshield and preventblade-to-blade contact.

The conventional control approach relies upon intricate software controland position sensing along the wipe pattern. This undesirably requiresseparate motor control circuitry and a reliance on the movement of thewiper motors to provide positional feedback. Generally, motor positionfeedback has been used in brushless dc motors by sensing the changes inthe commutation of the motor windings. This has sometimes been doneusing Hall Effect sensors, as disclosed, for example, in U.S. Pat. No.4,680,515 to Crook; U.S. Pat. No. 4,723,100 to Horikawa et al.; and U.S.Pat. No. 4,897,583 to Rees. The Hall Effect sensors have also been usedto count pulses of a pulse train generated by a rotating toothed wheelto produce position signals for operational control of the motor. Whilesuitable for use in windshield wiper systems, the use of the above-notedbrushless dc motor controllers in a windshield wiper system that usesseparate position sensors for coordination of the wipers can result inan unnecessarily complicated design. Also, any loss of power to thesystem will disorient and confuse these sensors such that the wiper armposition becomes an unknown. Thus, windshield wiper systems that employpulse train type sensors suffer from the disadvantage that they easilyloose the accurate position of the windshield wiper blade during commonoperating conditions and therefore suffer a loss of control in thesecircumstances.

The build-up of snow and ice on the windshield complicates the controlof blade movement and the ability to accurately determine wiper armposition and can impede the movement of the blades unevenly, causing oneblade to move faster than the other. When encountering this problem,electronically controlled wiper systems presently known in the art canoften become unsynchronized and may clash as they become unable tomaintain their sense of wiper arm position. Thus, there is a need in theart for a direct drive motor for a windshield wiper system that hasintegrated control circuitry and achieves position sensing such that thewiper arms position is known regardless of rotation and such that thedetected arm position is not lost during power loss or loss of motion.

Conventional dual direct drive wiper systems use high-speed dc motors.This is undesirable, as it requires large counter-rotational forces tostop and then reverse the wiper arm at the end of its sweep. Also, largecurrent draws are necessary to produce the counter-rotational forceswhich causes repetitive surges in the supplied power and induces greatamounts of electro-magnetic interference to the immediately surroundingparts of the vehicle. With a high-speed dc motor, it is also problematicto vary the speed of the wiper arm as it sweeps across the windshield,if this is desired as part of a sweeping pattern or predeterminedclearing scheme. These drawbacks stem from the conventional constructionof direct drive wiper motors, which have either a one-to-one directdrive or an inefficient gearing assembly to differ the wiper arm speedfrom motor speed. Thus, there is also a need in the art for a directdrive motor for a windshield wiper system that is efficient andcontrollable at a lower drive speed and that is electro-magneticallyclean.

One other drawback to conventional wiper motor systems has recentlyemerged. The conventional direct drive windshield wiper systems employdc motors that are of the standard 12-volt operating standard. This ispresently adequate, but current design trends are moving toward moreefficient 42 volt based automotive electrical systems. The change overto a 42 volt automotive electrical systems will be highly problematicfor the prior dual direct drive wiper systems and presents aconsiderable drawback as the prior systems are not compatible.Therefore, there is a need to not only provide a direct drive windshieldwiper system that overcomes the above-mentioned drawbacks but that alsohas the ability to be employed in the newly emerging 42 volt automotiveelectrical system environment.

SUMMARY OF THE INVENTION AND ADVANTAGES

Each of the disadvantages that presently exist in the related art asdiscussed above is overcome in the direct drive windshield wiperassembly of the present invention. The windshield wiper assemblyincludes at least one motor having an output shaft and a windshieldwiper operatively connected to the output shaft such that the windshieldwiper may be driven in repeated wiping motion across the surface of thewindshield. The motor includes a stator adapted to provide anelectromagnetic flux and a rotor assembly supported for rotation aboutthe stator. The rotor assembly includes a back iron that defines aninner circumference and a plurality of magnets disposed in spacedparallel relationship relative to one another about the innercircumference of the back iron and in radially spaced relationship aboutthe stator. The rotor assembly is operatively connected to the outputshaft and responsive to the electromagnetic flux generated by the statorso as to provide a rotational force to the output shaft to drive thewindshield wiper in repeated wiping motion across the windshield.

In another embodiment of the present invention, the direct drivewindshield wiper assembly includes at least one brushless DC motorproviding a drive torque through an output that is rotatable about thelongitudinal axis of the motor and a windshield wiper that is driven bythe motor about the longitudinal axis in a repeated wiping motion acrossthe surface of a windshield. The motor includes a planetary gear sethaving an output shaft. The gear set is coaxially disposed relative tothe rotational output and the longitudinal axis of the motor andoperatively interconnects the drive torque and the windshield wiper. Thegear set is further operable to reduce the speed of the rotationaloutput of the motor to the windshield wiper through the output shaft ofthe gear set.

The direct drive windshield wiper assembly according to the presentinvention may also include a position sensor that is adapted to sensethe speed and position of the motor output. The position sensor includesa flux ring holder that is fixedly mounted within the motor and isadapted to support at least one flux ring thereupon. A magnet holder isoperatively connected to the output of the motor and is adapted forrotation therewith. The magnet holder supports at least one magnet inspaced parallel relationship with respect to the flux ring. In addition,the motor includes a position sensor circuit that produces signalscorresponding to the rotational speed and position of the windshieldwiper.

In another alternate embodiment, the direct drive windshield wiperassembly of the present invention includes at least one brushless DCmotor that provides a drive torque through an output and a windshieldwiper that is driven by the motor in a repeated wiping motion across thesurface of the windshield. The motor includes a housing and a statorfixedly supported within the housing. A rotor is rotatably supportedwithin the housing and is disposed about the stationary stator. Therotor is operatively connected to the output of the motor andcontrollable to rotate in either direction thereby providingbi-directional rotation to the windshield wiper. In addition, the directdrive windshield wiper assembly further includes a latching mechanismthat acts to secure the rotor and thus the output of the motor in anon-rotational disposition when the motor is off.

In still another embodiment of the direct drive windshield wiperassembly of the present invention the motor may further include aprogrammable control circuit that acts to control the operation of themotor so as to affect the position and speed of the windshield wiper.

One advantage of the windshield wiper system of the present invention isthat it utilizes individual direct drive motors for coordinated, butmechanically independent control of the windshield wiper. The presentinvention acts to maximize the angular velocity of the blade assembliesbetween in-wipe and out-wipe positions thereby reducing the duration ofeach wipe cycle while limiting the noise and inertia loading byefficiently structuring a brushless DC motor and by controlling thevelocity of the blade assemblies as they approach the wipe limits whenthe direction of the wiper assembly must be reversed.

Another advantage of the windshield wiper system of the presentinvention is that the sweep speed and velocity of the wiper assemblywithin the wipe cycle may be controlled to reduce the time the wiperassembly spends in the driver's view area of the windshield therebyreducing the visual obstruction of the wiper assembly.

Another advantage of the windshield wiper system of the presentinvention is that it eliminates the complex linkages employed in therelated art to convert single angular motion of the wipe motor intotwo-way linear reciprocal motion used to drive one or more windshieldwiper arms. Thus, the present invention requires a smaller operationalenvelope than devices employed in the related art.

Another advantage of the present invention is that it employs a positionsensor that senses the rotational speed and position of the windshieldwiper and will not loose its position parameter even in the event of apower loss. Thus, the windshield wiper system of the present inventionwill not become unsynchronized and therefore will not clash due to aninability to maintain the sense of wiper arm position.

Another advantage of the present invention is that it employs a latchingmechanism that secures the motor and thus the output of the motor in anon-rotational disposition when the motor is off.

Another advantage of the present invention is that it includes anintegrated control circuitry that achieves position sensing such thatthe wiper arm position is known regardless of rotation and such that thedetected arm position is not lost during power loss or loss of motion.

Still another advantage of the windshield wiper system of the presentinvention is that it may be employed in either a standard 12 volt or themore efficient 42 volt-based automotive electrical system.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the invention will be readily appreciated as thesame becomes better understood by reference to the following detaileddescription when considered in connection with the accompanyingdrawings, wherein:

FIG. 1 is an assembled view of the preferred embodiment of the presentinvention of a direct drive windshield wiper assembly;

FIG. 2 is an exploded view of the assemblies of the preferred embodimentof the present invention;

FIG. 3 is a cross-sectional view of the assemblies of the preferredembodiment of the present invention and their physical relationship toeach other;

FIG. 4 is an exploded view of the motor housing assembly of thepreferred embodiment of the present invention;

FIG. 5 is an exploded view of the rotor assembly of the preferredembodiment of the present invention;

FIG. 5A is a perspective view of an alternate embodiment of the backiron and magnets of the present invention;

FIG. 5B is a cross-sectional top view of the back iron illustrated inFIG. 5A and disposed in radially spaced relationship about the stator;

FIG. 5C is an enlarged cross-sectional top view of the back ironillustrated in FIG. 5A;

FIG. 5D is a cross-sectional side view of the back iron illustrated inFIG. 5A;

FIG. 6 is an exploded view of the gear housing assembly of the preferredembodiment of the present invention;

FIG. 7 is an exploded view of the electronics housing of the preferredembodiment of the present invention;

FIG. 7A is an exploded detail view of the position sensor assembly ofthe electronics housing in the preferred embodiment of the presentinvention;

FIG. 8 is a block diagram of the programmable control circuit of thepreferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring now to the figures where like numerals are used to designatelike structure throughout the drawings, a direct drive windshield wiperassembly of the present invention is generally indicated at 10. As shownin FIG. 1, the direct drive windshield wiper assembly 10 includes atleast one motor 12 that rotatably drives a windshield wiper 14 acrossthe surface of a windshield 16. Generally speaking, the motor 12provides a drive torque through an output that is rotatable about thelongitudinal axis of the motor 12 so that the windshield wiper 14 isdriven about the same longitudinal axis in a repeated wiping motionacross the surface of the windshield 16. The motor 12 furthercontrollable to rotate in either direction, thereby providingbi-directional rotation to the windshield wiper 14. In addition, fromthe description that follows, those having ordinary skill in the artwill appreciate that the windshield wiper assembly of the presentinvention may encompass two or more motors 12, each that drive awindshield wiper 14 in repeated wiping motion across the surface of awindshield 16. It should also be appreciated that the motor 12 may be ofa brushless DC, a switched reluctance, or an induction type motorwithout departing from the spirit and scope of the invention. However,for purposes of description and not by way of limitation, it will bedescribed generally as a brushless DC motor in this specification. Inthe preferred embodiment, each motor 12 is electronically interconnectedand controlled in a manner that will be described in greater detailbelow.

Specifically, as best shown in FIG. 2, the motor 12 includes a motorassembly, generally indicated at 20, a gear set assembly, generallyindicated at 22, operatively supported on one end of the motor assembly20 and an electronics assembly, generally indicated at 24, operativelysupported on the motor assembly 20 opposite the gear set assembly 22. Inthe preferred embodiment, the gear set assembly 22, and the electronicsassembly 24 are made of a plastic material composition formed by aninjection molding process for ease of construction, weight, strength,and environmental considerations. The motor assembly 20 is made of amagnesium alloy to remove heat and dampen electromagnetic interferenceand may be formed by an injection molding process. It should beappreciated by those of ordinary skill in the art that any of a varietyof materials may be successfully employed in the manufacture of theseparts.

As shown in FIGS. 3 and 4, the motor assembly 20 includes a housing 21that is formed in a general cup shape and encloses a stator 26 that isfixedly supported within an inner cavity 28 of the motor housing 21, anda rotor assembly 30 that is rotatably supported within the motor housing21 and disposed about the stationary stator 26. The stator 26 is formedin the shape of an annular ring having an open center and is disposedover a hollow cylindrical center hub 32 within the motor housing 20. Thestator 26 is constructed in a known manner having either a plurality ofstamped lamination pieces 34 stacked together or being of a one-piecemolded powder metal. The stator 26 is conventionally wire wound and hasan end plate 36 that is adapted to readily retain the ends of the wirewindings while offering a plurality of connector points 38 forconnection to the electronics assembly 24. The connector points 38 ofthe stator end plate 36 are accessible through openings 40 in the baseof the motor housing 21. The center hub 32 of the motor housing 21 alsohas a bearing recess 50 (FIG. 4) that receives and retains the rotorbearing 52 (FIG. 3). The rotor bearing 52 serves to rotatively supportthe rotor assembly 30 as described below.

As shown in FIGS. 3 and 5, the rotor assembly 30 includes a back iron60, a motor magnet 62 that is operatively supported by the back iron 60and a rotor cap 64. A sun gear 66 is operatively mounted to the rotorcap 64 as will be described in greater detail below. The back iron 60 isgenerally shaped as a sleeve having an inner circumference 68 upon whichthe motor magnet 62 is molded. Alternately, the motor magnet 62 may beglued and pressed into the back iron 60. Thus the back iron 60 providesrigid support for the motor magnet 62. In the preferred embodiment, amolded permanent magnet of a composition of Nb—Fe—B (Niobium, Iron, andBoron) is desirable for its strength and durability. The Nb—Fe—Bcompound is also easy to mass produce and produces tight, short magneticflux lines, which generate a magnetic field that is stronger than othermoldable magnetic compounds allowing the magnet to be smaller andlighter. However, it will be appreciated by those having ordinary skillin the art that any of a variety of magnetic compounds may be used orthat non-molded magnets may also be employed without departing from thespirit and scope of the present invention.

An alternate embodiment of the back iron and associated magnets isgenerally illustrated in FIGS. 5A-5D, where like numerals, some of whichare primed, are used to designate like structure illustrated in FIG. 5.In this embodiment, the back iron 60′ defines an inner circumference 68′and a plurality of magnets 62′ are disposed in spaced parallelrelationship relative to one another about the inner circumference 68′of the back iron 60. As best illustrated in FIG. 5B, the plurality ofmagnets 62′ are also disposed in radially spaced relationship about thestator 26. As best shown in FIGS. 5A, 5C and 5D, the magnets 62′ have arectangular shape defining a major axis disposed generally parallel tothe axis of the output shaft of the motor 12. In addition, the magnets62′ define north and south poles at opposite ends of the magnets.Moreover, the plurality of rectangular magnets 62′ are arranged suchthat the north pole of each magnet is disposed in spaced parallelrelationship to the south pole of an adjacent magnet 62′. The back iron60′ is tubular and defines a pair of ends 67, 69. As best shown in FIGS.5A and 5D, at least one of the poles on each of the plurality of magnets62′ is longitudinally spaced from an associated end of the back iron60′. This space is designated 71 in these figures.

The inner circumference 68′ of the back iron 60′ includes a plurality ofchord surfaces 63 that correspond to the plurality of magnets 62′. Eachone of the plurality of magnets 62′ is operatively mounted to thecorresponding one of the plurality of chord surfaces 63 on the innercircumference 68′ of the back iron 60′. Similarly, the innercircumference 68′ of the back iron 60′ further includes a plurality ofarcs 65 that are disposed between adjacent ones of the plurality ofchord surface 63. The chord surfaces 63 are formed, in one embodiment,using a broaching operation. In this way, the chord surfaces 63 allowfor the flat, rectangular magnets 62′ to be mounted to the back iron 60′in an efficient and precise manner. An adhesive may be used to mount themagnets 62′ in this way. This structure allows for a smaller air gap 73that is defined between the plurality of magnets 62′ and the stator 26,thus increasing the torque output of the motor 12. The increase in thetorque output of the motor in turn allows for a reduced length of theback iron for any given torque output. This further reduces the cost ofthe magnets 62′ as well as the back iron 60′.

As noted above, the back iron 60′ forms a part of the rotor assembly 30.As explained in greater detail below, the rotor assembly 30 isoperatively connected to the output shaft of the motor 12 and isresponsive to the electromagnetic flux generated by the stator 26 so asto provide a rotational force to the output shaft to drive thewindshield wiper in repeated wiping motion across the windshield.

In the preferred embodiment illustrated in FIGS. 5A-5D, the rectangularmagnets 62′ are sintered magnets made of a Nb—Fe—B (niobium, iron, andboron) composition. However, like the embodiment illustrated in FIG. 5,those having ordinary skill in the art will appreciate that any varietyof magnetic compounds may be used and that non-sintered magnets may beemployed without departing from the the scope of the present invention.Furthermore, those having ordinary skill in the art will appreciate fromthe description that follows that the back iron and magnet assemblyillustrated in FIGS. 5A-5D is interchangeable with that illustrated inFIG. 5.

The disk-shaped rotor cap 64 is fixedly mounted to the upper edge 72 ofthe rotor back iron 60, so that the rotor assembly 30 forms a cup-shapethat is received by the motor housing 21. The rotor cap 64 has a centralopening 74 and a bearing surface 76. The bearing surface 76 is disposedon the inner side of the rotor cap 64 and is received by and engaged tothe rotor bearing 52 that is disposed within the center hub 32 withinthe motor housing 21. The central opening 74 of the rotor cap 64 issplined at 78 and adapted to complementarily receive in splinedengagement the gear teeth 80 of a sun gear 66. Alternately, the sun gear66 may be operatively interconnected to the rotor cap 64 using any othersuitable means commonly known in the art. The sun gear 66 also has acentral opening 82 and may include a truncated conical head 84 at oneend.

As shown in FIGS. 3 and 6, the gear assembly 22 includes a gear housing23 that is formed in a general cup shape and includes a planetary gearset, generally indicated at 86. The gear set 86 is coaxially disposedrelative to the rotational output of the rotor assembly 30 and is thuscoaxial to the longitudinal axis of the motor 12 and operativelyinterconnects the motor drive torque and the windshield wiper 14. Thegear set 86 is further operable to reduce the speed of the rotationaloutput of the motor 12 to the windshield wiper 14 through the outputshaft 88 of the gear set 86.

In the preferred embodiment illustrated in these figures, the gear set86 includes an output shaft 88, a ring gear 90, a carrier 92, and aplurality of planet gears 94 operatively supported by the carrier 92.The planet gears 94 are supported within a two-piece carrier 92 inmeshing relationship with the ring gear 90 of the planetary gear set 86and the sun gear 66 of the rotor assembly 30. The ring gear 90 isfixedly disposed within the inner circumference 96 of the gear housing22. The output shaft 88 has a wiper end 98 and a sensor end 100. Thesensor end 100 defines a predetermined diameter that can be narrowerthan the wiper end 98.

The wiper end 98 of the output shaft 88 extends outward through acentral opening 102 of the gear housing 23. The exposed portion 104 ofthe wiper end 98 is machined in a manner to receive and retain the endof a windshield wiper 14. It should be appreciated by those of ordinaryskill in the art that the exposed portion of the wiper end 98 of theoutput shaft 88 may be splined or otherwise keyed to rotationally securethe wiper 14. However, as will be discussed in greater detail below,there is no necessity for orienting the wiper 14 to a particular angularposition of the output shaft 88 as the “park”, and lower and upper sweeplimits of the wiper 14 are programmable and software calibrated on thevehicle once the direct drive windshield wiper assembly 10 is installed.

As best shown in FIG. 3, the output shaft 88 also has a carrierinterface portion 106 adjacent to the exposed portion 104. The carrierinterface portion 106 is received by, and operatively connected to, ahollow center sleeve 108 of the carrier 92. It should be appreciatedthat the carrier 92 may be connected to the output shaft 88 by splines,a keyway, or any of a variety of connection methods. Thus, the centralopening 102 of the gear housing 23 has an inner diameter sufficient toreceive the combined carrier center sleeve 108 and the output shaft 88.As can be seen in FIGS. 3 and 6, a spring 110 and a spring washer 112have an inside and outside diameter that allows them to be received bythe gear housing central opening 102 while being disposed over theoutput shaft wiper end 98 above the carrier center sleeve 108. A pushnut 114 and push nut washer 116 are disposed over the wiper end 98 ofthe output shaft 88, such that the push nut washer 116 rotatively rideson the outer end surface 118 of the gear housing central opening 102while causing a compressive biasing force to be placed on the spring 110and spring washer 112 within the gear housing central opening 102against the end of the carrier center sleeve 108. The push nut 114serves to lockingly engage the output shaft 88 and hold the push nutwasher 116, the spring 110, and the spring washer 112 in place withoutthe need of threads. The compressive, or biasing force, imparted by thespring 110 serves to maintain the longitudinal alignment of thecomponents of planetary gear set 86 with the rotor assembly 30 and thestator 26, as the carrier 92 is supportively biased against thetruncated conical lip 84 of the sun gear 66. Also, the biasing force ofthe spring 110 bears against the lip 84 so that the planet gears 94maintain their alignment against the sun gear 66, as seen in FIG. 3.

The sun gear 66 is operatively driven by the rotational output of thebrushless DC motor 12 by its direct connection to the rotor cap 64 ofthe rotor assembly 30. As noted above, the carrier 92 is operativelyconnected to the output shaft 88, and the ring gear 90 is fixedlymounted to the gear set housing 23 in a fixed position. Thus, inoperation, rotation of the sun gear 66 causes the planet gears 94 torevolve around the ring gear 66 thereby rotating the carrier 92 and theoutput shaft 88 of said gear set about the longitudinal axis of themotor. The rotor assembly 30, gear set 86, and output shaft 88 withinthe motor 12, are all in coaxial relationship to each other.

The motor housing 21 further includes a recess 42 that is designed toaccommodate a portion of a latching mechanism, generally indicated at44. The back iron 60 of the rotor assembly 30 includes a plurality ofnotches 70 disposed about its lower edge. The latching mechanism 44 actsto secure the rotor assembly 30 and thus the output shaft 88 of the gearset 86 in non-rotational disposition when the motor 12 is off. Morespecifically, the latching mechanism 44 includes an electromagneticactuator 45 and a latching member 46. In the preferred embodiment, theelectromagnetic actuator is a solenoid 45 that operatively drives thelatching member 46 to a retracted position. In addition, the latchingmechanism 44 includes a biasing member 48 that produces a biasing forcein a direction opposite of that produced by the solenoid 45 such thatthe latching member 46 engages at least one of the notches 70 formed onthe back iron 60 of the rotor assembly 30 thereby immobilizing it. Onthe other hand, the electromagnetic force generated by the solenoid 45is sufficient to overcome the biasing force to allow rotation of therotor which allows the latching member 46 of the latching solenoid 44 todisengage from the notch 70 and thereby releasing the back iron 60allowing it to rotate. In the preferred embodiment, the biasing member48 is a coiled spring that normally biases the latching member 46 to theengaged position securing the rotor assembly 30 and thus, the outputshaft 88 in non-rotational disposition when the motor 12 is off.

The gear housing 23 further includes a plurality of recessed bores 120formed in the outer surface that receive and retain a like number ofthreaded inserts 122. The treaded inserts 122 provide mounting pointsfor the direct drive windshield wiper assembly 10 to locate and securethe assembly within the vehicle. Alternately, the direct drivewindshield wiper assembly 10 may be mounted using a flange mountdisposed upon the gear housing 23 or any other suitable mounting methodcommonly known in the art. A rubber boot 124 is sealingly disposed overthe output shaft wiper end 98 and the gear housing central opening 102in a manner that prevents environmental elements from entering the motorassembly 12 but allows the output shaft 88 to freely rotate asnecessary.

As best seen in FIG. 3, the output shaft 88 is received through acentral opening in the sun gear 66 and through the center opening of thebearing assembly 52, and extends inward into the hollow center hub 32 ofthe motor housing 21. The output shaft 88 is not physically connected toeither the sun gear 66 or the rotor bearing 52 but is free to rotatewithin them. In this manner, the sensor end 100 of the output shaft 88is operatively connected to a position sensor as discussed below.

As illustrated in FIG. 7, the electronics assembly 24 of the motor 12includes a position sensor assembly 126, an end cap 128, and aprogrammable control circuit 130. As shown in detail in FIG. 7A, theposition sensor assembly 126 is disposed upon the end cap 128 and isadapted to sense the speed and position of the output shaft 88. Theposition sensor assembly 126 includes a flux ring holder, generallyindicated at 132, that fixedly supports at least one flux ring 134, anda magnet holder, generally indicated at 136, that fixedly supports atleast one magnet 138 in spaced parallel relationship with respect to theflux ring 134. The position sensor assembly 126 also includes an outputshaft coupler, generally indicated at 140, and a position sensorcircuit, generally indicated at 142 for a purpose that will be explainedin greater detail below.

The flux ring holder 132 is generally disk shaped having an end face144. The flux ring holder 132 is fixedly mounted to the end cap 128 andhas an annular shaped slot 146 in its end face 144 to receive and retainthe at least one flux ring 134. The flux ring 134 is formed from amagnetically permeable material that is electrically capable ofdetecting variations in magnetic flux lines as they pass over andthrough the ring. The flux ring holder end face 144 also has an extendedcylindrical protrusion 148 that extends toward the magnet holder 136.

The magnet holder 136 is generally cylinder shaped having an end face150 that is designed to abut the flux ring holder end face 144. Themagnet holder end face 150 has a receiving bore 152 that receives thecylindrical protrusion 148 of the flux ring holder 132, which serves asa rotational axis for the magnet holder 136. The magnet holder 136further includes an annular shaped slot 154 in its end face 150 that isadapted to receive and retain an at least one magnet 138. On the endopposite to the end face 150, the magnet holder 136 has a recessedcavity 156 that receives and retains the output shaft coupler 140. Theoutput shaft coupler 140 has a magnet holder portion 158 and an outputshaft receiving end 160. The output shaft coupler 140 serves as thephysical connection between the position sensor assembly 126 and theoutput shaft sensor end 100.

The magnet holder portion 158 of the output shaft coupler 140 is formedin a shape complementary to be received and retained by the recessedcavity 156 of the magnet holder 136 and the output shaft receiving end160 is formed in a shape to receive and retained the sensor end 100 ofthe output shaft 88. A foam insert 162 is disposed within the recessedcavity 156 for shock absorption. It should be appreciated by thosehaving ordinary skill in the art that the shaped portions of therecessed cavity 156 and the output shaft coupler 140 may be formed inany suitable geometric shape, as it is not necessary to have a zerodegree orientation based on a physical reference point for the outputshaft 88. As will be discussed in greater detail below, the “park”, andthe inner and outer sweep limits to the wiper, and hence the outputshaft 88 of the direct drive windshield wiper system 10, are programmedinto the present invention after it is installed on the vehicle.

The position sensor circuit 142 is supported upon the flux ring holder132 and is in electrical communication with, and receiveselectromagnetic signals from, the flux ring 134. More specifically, theposition sensor circuit 142 measures the flux variations generatedwithin the flux ring 134. The position sensor circuit 142 is also inelectrical communication with the programmable control circuit 130. Theflux variations from the flux ring 134 are sensed as two quadratureelectrical signals as the magnet 138, held within the magnet holder 136,is rotated about the stationary flux ring 134 by the rotating outputshaft 88. In the preferred embodiment, a plurality of flux sectors 135form the flux ring 134 and are offset eccentrically from a single magnet138. The flux ring 134 is positioned such that the magnetic fieldinduced within the flux ring 134 varies uniquely for all angulardisplacements in the rotation of the output shaft 88. In this manner,the position sensor circuit 142 produces an instantaneous signal that isrepresentative of a particular angular displacement of the output shaft88 thereby allowing the position sensor 126 to act as an absoluteposition sensor for detecting the angular position of the output shaft88. Additionally, as the output shaft 88 moves, the position sensorcircuit 142 continuously produces position signals. Dynamically, thisseries of signals allows the direction and speed of the output shaft 88to be determined. In the preferred embodiment, the magnet 138 isbipolar, however it should be appreciated that the magnet 138 may alsohave multiple poles about its circumference.

In another non-limiting embodiment, at least one magnet 138 of anannular ring shape is offset eccentrically from a single flux ring 134.In either case, since the position of the magnet 138 varies the flux, nopower is required by the position sensor assembly 126 to follow theposition of the output shaft. Thus, if the power to the windshield wiperassembly 10 fails or the power to the vehicle is removed, the windshieldwiper assembly 10 does not lose its orientation and can instantlyrecover its positional information after power restoration. Therefore,the position sensor circuit 142 interprets the magnetic flux signals andproduces an output denoting the absolute position of the output shaft 88and routes that signal to the programmable control circuit 130.

Alternately, the position sensor assembly 126 may be replaced by a parksensing assembly. The park sensing assembly includes a magnetic “parkplatform” disposed on the output shaft and a “park” hall sensor mountedwithin the motor to detect the park platform. When the wiper assembly 10is mounted to a vehicle, the wiper assembly 10 is oriented so thatduring the first half of the wipe area, the park platform is positionedsuch that it covers the park sensor. If the wiper assembly 10 isoperating and the power is lost and then recovered, the park hall sensorwill be in a relative position to either sense the park platform or not.If the park sensor senses the park platform, then the output shaft is inthe first half of the wipe area and it is safe for the microprocessor toperform an out-wipe. If the park hall sensor does not sense the platformthen the output shaft must be on the second half of the wipe area and itis safe for the microprocessor to perform an in-wipe. In either case,the park sensor will detect the platform edge, which is used as theposition reference along the wipe path. This platform crossing providesopportunity for the microprocessor to obtain correct position. It shouldbe noted that this embodiment must be used with additional physicalsensors positioned about the motor windings that would provide a “pulsetrain” of position signals for an accurate determination of wiper armposition. This pulse train would be available with the “sensored”commutation scheme discussed below.

The programmable control circuit 130, generally indicated in FIG. 7 isshown in block diagram form in FIG. 8. The control circuit 130 is agroup of circuits mounted on a printed circuit board 164 that isdisposed within the electronics housing 24 that provides electric andelectronic circuits to control the operation of the motor 12 so as toeffect the position and speed of the windshield wiper 14. Theprogrammable control circuit 130 includes a 3 (three) phase motor drivercircuit 166, a current sensor 168, a back-electromotive force (BEMF)sensor 169, a voltage regulator 170, a solenoid driver 172, amicroprocessor 174, and at least one serial communications interface176. The circuit board 164 also includes a 6-pin connector 178 and an8-pin connector 180 to allow electrical communication with the othercomponents of the system.

The 3-phase motor driver circuit 166 provides electromotive force todrive the motor. The 3-phase motor driver circuit 166 is a bridgecircuit that utilizes 6 (six) N-Channel power MOSFET semiconductordevices in three half-bridges between the input voltage and the return,or ground. The microprocessor 174 provides pulse width modulated (PWM)triggering, or biasing, signals to the 3-phase bridge driver circuit166. These signals drive the MOSFETs and produce three separate voltagesto apply to the stator windings. The 3 half-bridges produce the threeoutput voltages in three separate phases that are provided in a rampingsequence to the windings of the stator 26 so that successive magneticfields are generated and varied within the windings of the stator 26.The generation of successive magnetic fields within the stator windingsacts to angularly repel the magnetic fields of the rotor assembly 30,thereby driving the rotor 30, the planetary gear set 22, and ultimately,the output shaft 88. The modulation of the PWM signals is performed in aknown manner to control the duty cycle of the signals to the MOSFETs.This controls the duration of the phases of the 3-phase voltage output,thereby controlling the rotational speed of the rotor 30.

In producing the varying magnetic fields within the stator windingsthereby creating rotor rotation, the ramping voltage waveform may beeither sinusoidal or trapezoidal. Thus, the production of the threephase voltages from the 3-phase motor driver circuit 166 can be referredto as either sinusoidal or trapezoidal commutation. To properly controland time the commutation to drive the rotor 30 in the desired manner,the rotor position must be accurately determined, or sensed, as itrotates. This position sensing of the rotor 30 is used as feedback tothe microprocessor 174. In the preferred embodiment, the rotor positionis derived in a “sensorless” manner, meaning that the rotor position isderived electronically and indirectly to provide the necessary feedbackto the microprocessor 174 with no additional physical sensors used aboutthe motor. In sensorless commutation configurations, either aback-electromotive force (BEMF) sensor 169 (comprised of a resistivevoltage divider and a low pass filter) or the current sensor 168 is usedto detect the commutation, depending on the type of ramping waveform.

The preferred method of commutation (and rotor position detection) usesa trapezoidal waveform. As such, the preferred embodiment of the presentinvention uses a sensorless trapezoidal commutation scheme, which has aBEMF sensor 169 to detect the commutation electrically and indirectlyfrom the stator windings to provide feedback to the microprocessor 174.More specifically, although called a sensor, by detecting a signalelectronically and indirectly, the BEMF sensor 169 of the presentinvention is not a sensor in the common use of the word. The BEMF sensor169 actually detects an induced magnetic flux signal within a portion ofthe stator windings and the microprocessor 174 uses this flux signalfeedback to calculate the rotor position using an “extended Kalmanestimator” algorithm. The microprocessor 174 then uses the calculatedrotor position to generate the necessary PWM signals (to feed to the3-phase bridge driver circuit 166) to properly time the trapezoidalcommutation. In this commutation scheme, the current sensor 168 is onlyused to provide signals for motor current regulation and calculation ofthe output torque of the motor. It is not involved in the commutation.

In an additional non-limiting embodiment, sensorless sinusoidalcommutation may be employed. In this case, the current sensor 168 iselectrically connected to the ground side of the three half bridges (6MOSFETs) or in such a manner as to detect the current of two of thethree phases. Again, this is a sensorless (indirect) manner ofdetermining rotor position, as the sensed current signals are fed backto the microprocessor 174 to calculate the rotor position using the“extended Kalman estimator” algorithm. The microprocessor 174 then usesthe calculated rotor position to generate and provide the necessary PWMsignals to control and time the sinusoidal commutation.

In other non-limiting embodiments, additional sensors may be physicallylocated about the motor to provide a “sensored” commutation. Forexample, three Hall effect sensor devices may be physically disposedwithin the spacing of the stator windings, 120 electrical degrees apart,to provide feedback signals to the microprocessor 174 as a directlysensed feedback to control and time a trapezoidal based commutation.

The solenoid driver 172 is in electrical communication with the latchingsolenoid 44 disposed within the motor housing 20 and is operable tocontrol the latching solenoid 44. When the solenoid driver 172 actuatesthe latching solenoid 44 it overcomes the biasing force of the biasingmember 48 and withdraws the latching arm 46 from the rotor 30 allowingthe rotor assembly 30 to rotate. In one preferred embodiment, thesolenoid driver 172 may be of an “H” bridge type.

It should be appreciated that the microprocessor 174, as a device, isgenerally described and may be a complex microprocessor or any ofanother lesser type of integrated circuit such as a digital signalprocessor. As such, the microprocessor 174 includes a memory that isprogrammable to retain at least one predetermined windshield wipercontrol scheme. It should be appreciated by those of ordinary skill inthe art that the microprocessor 174 has a memory capable of retaining astored data program having instructions for the control of the wipermotor assembly 12. Thus, the microprocessor 174 may employ a ROM(read-only-memory) that permanently stores an operational program, or a“flash” type memory that may be changed or updated, as well as avolatile RAM (random access memory). In the preferred embodiment, themicroprocessor 174 has a semi-permanent flash memory, which is loaded byan external computer or a programming device. The flash memory retainsits stored program data even after power is removed from the device, butmay be updated or refreshed as necessary at any time during the servicelife of the wiper motor. The RAM of the microprocessor 174 is used totemporarily store data during the execution of the stored program whileoperating the wiper motor 12. The microprocessor 174 further includes anA/D (analog/digital) converter, a digital interface, and time capturecircuitry. The A/D converter allows the digitally based microprocessordevice to interact with the various circuits and devices that are analogbased. The digital interface allows communication to digitally basedcomponents and circuits, and the time capture circuitry allows fortiming and control of the various signals and operations under thecontrol of the microprocessor 174.

The serial interface circuit 176 has a Local Interconnected Network(LIN) physical layer. The LIN layer allows interconnection between thetwo wiper motor assemblies 12 of a windshield wiper system through theuse of a single wire connection. In this manner, the individualwindshield wiper motor assemblies can communicate and the pre-determinedprograms stored in the flash memories can coordinate the wiper movementsacross the windshield. In the preferred embodiment, the serial interfacecircuit 176 uses two LIN layer circuits. The first LIN is for theinterconnection with the vehicle. The second LIN is for communicationwith the second wiper motor. It should be appreciated by those ofordinary skill in the art that the serial interface and the LIN physicallayers may be incorporated within the microprocessor 174 and that otherknown types of intercommunication networks, such as a control areanetwork (CAN) for example, may also be employed with the direct drivewindshield wiper assembly 10.

The preferred embodiment of the present invention is adapted to operatewithin a 12 volt DC environment, as is standard within the Americanautomotive industry. However, in another non-limiting embodiment, thepresent invention is adapted to be operable in a 42 volt or comparablevehicle operating environment, which are currently being developed for,and/or are evolving in, foreign and domestic automotive markets.

The end cap 128 physically supports the printed circuit board 164, thelatching mechanism 44, and the position sensor assembly 126. The end cap128 is generally cup shaped having an open central cavity 182. As shownin FIG. 3, the printed circuit board 164 is disposed in bottom of theend cap 128, thereby closing off and sealing the open central cavity 182from the ambient environment and protecting the enclosed electroniccomponents. The end cap 128 has extension connectors 184, positionsensor connectors 186 (FIG. 7), an external electrical connector 188 andlatching solenoid housing 190. The extension connectors 184 extendupward through the base of the motor housing 21 and have statorelectrical contacts 192, which clip into and electrically connect withthe connector points 38 of the stator end plate 36. The statorelectrical contacts 192 also have circuit board ends 194, which aredisposed in a manner within the end cap 128 that allows them to engageand interconnect with certain contacts within the 8-pin connector 180 ofthe printed circuit board 164. The position sensor connectors 186 extendupward in a manner to engage the electrical contacts of the positionsensor circuit 142. Similar to the stator electrical contacts 192, theposition sensor connectors 186 also have circuit board ends 196, whichare disposed in a manner within the end cap 128 that allows them toengage and interconnect with certain contacts within the 6-pin connector178 of the printed circuit board 164.

The external electrical connector 188 has a recess 198 and a locking tab200, or the like, which provides an environmentally protectedinterconnection with a wiring harness connector of the vehicle (notshown) in a typical manner. The external electrical connector 188 alsoincludes a series of electrical contacts 202 that provide power andground sources to the printed circuit board 164, and the LIN physicalconnections for the serial interface circuits 176. The latching solenoidhousing 190 is a recessed compartment molded into the end cap 128 toreceive the body of the latching mechanism 44. Solenoid electricalconnectors 204 extend from the latching mechanism 44 through the end cap128 to the 6-pin connector 178 on the printed circuit board 164. A venthole 206 is disposed in the end cap 128 at the bottom of the latchingsolenoid housing recess 190. It contains a membrane 208 that allows thepassage of air but not moisture.

In operation, the direct drive windshield wiper assembly 10 is installedin a motor vehicle in a position relative to a windshield such that awiper 14, when attached to the output shaft 88 of the wiper assembly 10,can sweep across a portion of the windshield. A flash programming device(not shown) is connected to the external electrical connector 188 of thewiper assembly 10. It should be appreciated by those having ordinaryskill in the art that a flash programming device may be interconnect tomore than one wiper assembly or through a vehicle serial data bus, orthe like, depending on the wiring of the vehicle and if data businterconnections are used between vehicle systems. The flash memory ofthe microprocessor 174 is then “flashed” or loaded with a predeterminedwiper control program, which contains specific parameters, such as, thewipe area of the windshield, the predetermined in-wipe and out-wipepositions of the windshield wiper blade, and the desired wiper speedprofiles, as well as dynamic control parameters of motor position,speed, torque and current. The wiper assembly is then calibrated as tothe lower and upper sweep limits by placing the wiper in the appropriatephysical position then programming that position in the memory. Itshould be appreciated that a “park” position is then either programmedinto the assembly or is calculated by a programming algorithm, whichwill move the wiper assembly 10 to the desired position and then locksit with the latching mechanism 44 when required. In this way, noadditional physical devices or apparatus are required to lock and holdthe wiper in its predetermined “park” position. If more than one wiperassembly 10 is employed on the vehicle, the microprocessors 174 of eachassembly may be coordinated in a predetermined windshield wiper controlscheme, one to the other, using the serial interface circuitry, toprovide the proper sweep profile and avoid a clash of wipers on thewindshield.

During wiper operation, the wiper assembly 10 utilizes the upper andlower sweep limits and the program stored in the flash memory to controlthe sweep of the wiper 14 across the windshield 16. It should beappreciated that various control programs can be stored in theprogrammable control circuit 130, which consider and incorporateexternal environmental parameters that influence the wiper operation.For example, the speed of the vehicle, the amount and type of ambientprecipitation, and the ambient and interior temperatures may be factoredinto the control of the sweep of the wiper. Additional weatherconsiderations, such as ice on the windshield and/or a build-up of snowat the lower end of the sweep may be countered by a particular change tothe sweep speed and torque of the wiper to clear such conditions, if theprogramming so dictates.

Thus, the windshield wiper system of the present invention utilizesindividual direct drive brushless DC motors for coordinated, butmechanically independent control of the windshield wiper. The presentinvention acts to maximize the angular velocity of the blade assembliesbetween in-wipe and out-wipe positions thereby reducing the duration ofeach wipe cycle while limiting the noise and inertia loading byefficiently structuring the DC motor and by controlling the velocity ofthe blade assemblies as they approach the wipe limits. In addition, thewindshield wiper system of the present invention eliminates the complexlinkages employed in the related art to convert single angular motion ofthe wipe motor into two-way linear reciprocal motion used to drive apair of windshield wiper arms. Thus, the present invention requires asmaller operational envelope than devices employed in the related art.

The present invention employs a position sensor that senses therotational speed and position of the windshield wiper and will not loosethese parameters even in the event of a power loss. Thus, the windshieldwiper system of the present invention will not become unsynchronized andtherefore will not clash due to an inability to maintain the sense ofwiper arm position. The present invention also employs a latchingmechanism that secures the motor and thus the output of the motor in anon-rotational disposition when the motor is off. Furthermore, thepresent invention includes an integrated control circuitry that achievesposition sensing such that the wiper art position is known regardless ofrotation and such that the detected arm position is not lost duringpower loss or loss of motion.

Finally, the windshield wiper system of the present invention may beemployed in either a standard 12 volt or the more efficient 42volt-based automotive electrical system.

The invention has been described in an illustrative manner. It is to beunderstood that the terminology that has been used is intended to be inthe nature of words of description rather than of limitation. Manymodifications and variations of the invention are possible in light ofthe above teachings. Therefore, within the scope of the appended claims,the invention may be practiced other than as specifically described.

1. A windshield wiper assembly comprising: at least one motor having anoutput shaft and a windshield wiper operatively connected to said outputshaft such that said windshield wiper may be driven in repeated wipingmotion across the surface of the windshield; said motor including astator adapted to provide an electromagnetic flux and a rotor assemblysupported for rotation about said stator, said rotor assembly includinga back iron that defines an inner circumference and a plurality ofmagnets disposed in spaced parallel relationship relative to one anotherabout said inner circumference of said back iron and in radially spacedrelationship about said stator, said rotor assembly operativelyconnected to said output shaft and responsive to the electromagneticflux generated by said stator so as to provide a rotational force tosaid output shaft to drive said windshield wiper in repeated wipingmotion across the windshield.
 2. A windshield wiper assembly as setforth in claim 1 wherein each one of said plurality of magnets has arectangular shape defining a major axis disposed generally parallel tothe axis of said output shaft of said motor.
 3. A windshield wiperassembly as set forth in claim 2 wherein each one of said plurality ofrectangular magnets defines a north and south pole at opposite endsthereof, and wherein the north pole of each magnet is disposed in spacedparallel relationship to the south pole of an adjacent magnet.
 4. Awindshield wiper assembly as set forth in claim 3 wherein said back ironis tubular and defines a pair of ends and where at least one of saidpoles on each of said plurality of magnets is longitudinally spaced froman associated end of said back iron.
 5. A windshield wiper assembly asset forth in claim 1 wherein said inner circumference of said back ironincludes a plurality of chord surfaces corresponding to said pluralityof magnets, each one of said plurality of magnets operatively mounted toa corresponding one of said plurality of chord surfaces on said innercircumference of said back iron.
 6. A windshield wiper assembly as setforth in claim 5 wherein said inner circumference of said back ironincludes a plurality of arcs disposed between adjacent ones of saidplurality of chord surfaces.